Mattress



E. A. KAMP Feb. 6, 1962 MATTRESS Filed Dec.

-f MM/Mu @aired freres Patent 3,019,456 MATTRESS Ewald A. Kamp, Chicago, lill., assigner to The Englander Company, lne., Chicago, 1li., a corporation of Dela- Ware Filed Dec. 8, 1953, Ser. No. 778,686 4' Claims. (Cl. E-ESS) This invention relates generally to mattresses and more speciiically to a mattress construction which features a seamless, liquid-repellent envelope for the mattress.

Because of the destructive proclivities of certain types of mental patients, mattresses intended primarily for use by `these persons must meet a number of stringent requirements. In order to prevent damage due to bed wetting or to any of a variety of other causes, such mattresses must be waterproof. A seamless exterior is of advantage in discouraging idle destruction of the mattress. Additionally, such mattresses must be rugged in order to withstand violent outbreaks, thrashing, being jumped upon, and the like. Desirably, these aims must not be achieved at the expense of providing a mattress that is generally uncomfortable.

Previous mattresses intended primarily for use by mental patients comprise a resilient mattress body having a rubber sheet folded over it, the edges of the rubber sheet being cemented in place. While providing a waterproof exterior, these prior art mattresses present seams where the edges of the rubber sheet are cemented; and these seams naturally provide points for destructive entry with the result that there is a general decrease in mattress life.

It is therefore a general object of the present invention to provide an improved mattress which is suitable for use by mental patients.

A further object of the invention is to provide a mattress which is Waterproof and which is highly resistant to destruction by frenzied or mischievous behavior.

A still further object of the invention is to provide a formed mattress having a seamless, waterproof exterior.

Additional objects and features of the invention pertain to the particular structure and arrangements whereby the above objects are obtained.

The structure in accordance with one embodiment of the invention includes a resilient inner core, a layer of felt surrounding the core, a nylon fabric envelope enclosing the felt-covered core, a thin layer of chlorosulfonated polyethylene applied over the nylon fabric envelope, and several coats of neoprene rubber applied over the chlorosulfonated polyethylene layer.

The structure of the invention will be better understood by reference to the following disclosure and drawings forming a part thereof wherein:

FIG. l is a perspective view of a mattress in accordance with the invention, the coating materials being cut away to reveal the individual layers;

FIG. 2 is a cross-sectional view through the mattress of FIG. 1; and

FIG. 3 is a fragmentary view detailing the side seam construction.

Referring now specifically to the drawings, there is shown a resilient core which may be advantageously fashioned from rubberized hair. Surrounding the core is a felt pad 12 which is employed in order to present a smooth, cushioned sleeping surface.

In constructing a mattress in accordance with the invention, the assembled unit comprising the core 10 and the pad 12 is inserted into a formed bag or envelope 14, desirably fashioned from a strong fabric such as nylon. Closure of the envelope 14 is preferably achieved by a zipper 16 lfastened along two adjacent sides of envelope 14. 'I'he zipper 16 may take the form of either a metal or a plastic zipper. Furthermore, other types of closures may be substituted for the zipper, for example, a friction closure. Y

in order to protect the zipper 16, it is contemplated that a strip 18 of material similar in nature to the material used in forming the envelope 1 4 be aiixed exteriorly over the zipper 116. Strip 13 may conveniently be cemented in place; and when envelope 14 and strip 1d are made of a nylon fabric, cementing may be achieved employing a solvent solution of chlorosulfonated polyethylene.

In order to render the mattress liquid-repellent and seamless, a number of layers 20 of an elastomeric material, such as neoprene rubber, are conveniently applied, as by spraying, over the surface of envelope 14. In the case where envelope 14 is made of nylon fabric, there is an advantage in precoating envelope 14 with a layer 22 of chlorosulfonated polyethylene prior to the application of the elastomeric coating. The chlorosulfonated polyethylene apparently acts as a bonding agent between the nylon and the neoprene rubber and prevents the neoprene from striking through the nylon.

The above descriptions are given with specic reference to a mattress intended primarily for use by mental patients. However, these descriptions should not be construed as limiting the invention. The mattress of this invention finds rather broad application in problem cases. For example, the mattress of the invention may also be used to advantage for infants. The true scope of the invention is defined in the following claims.

The invention is claimed as follows:

l. A11 exteriorly seamless mattress comprising a resilient inner core, a cushioning layer covering said core, an envelope enclosing the cushioning layer and core and serving to protect the cushioning layer against subsequently applied coating, fastener means associated with said envelope to secure the same in its enclosing position, a strip adhered to said envelope on opposite sides of the fastener means and overlying the fastener means, and a substantially continuous elastomeric coating covering the envelope and strip and rendering the mattress exteriorly seamless.

2. An exteriorly seamless mattress comprising a resilient inner core, a cushioning layer covering said core, an envelope covering said core and cushioning layer and formed of a material resistant to absorption of subsequent coating to protect the cushioning layer, fastener means associated with said envelope to secure the same in its enclosing position, a strip of material resistant to absorption of subsequent coatings and adhered to the envelope on opposite sides of the fastener means and covering the fastener means, and an elastomeric coating covering said envelope and strip and rendering the mattress seamless.

3. An exteriorly seamless mattress as claimed in claim 2, wherein the envelope and strip are formed of nylon.

4. An exteriorly seamless mattress as claimed in claim 3, wherein the coating comprises at least one layer of neoprene rubber with a layer of chlorosulfonated polyethylene separating the nylon envelope and nylon strip from the neoprene rubber.

References Cited in the le of this patent UNITED STATES PATENTS 1,583,334 Bloom May 4, 1926 2,232,646 Stone et al. Feb. 18, 1941 2,248,413 Rathbun Iuly 8, 1941 2,360,715 Perry Oct. 17, 1944 2,400,731 Armstrong May 21, 1946 2,406,830 Haman et al Sept. 3, 1946 2,742,652 Mautz Apr. 24, 1956 2,779,035 McMurray Jan. 29, 1957 

